Facility Diagnosis Control for Deterioration and KPI Balance
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Solution Overview
Problem
Existing facility diagnosis techniques struggle to prevent the progression of deterioration in manufacturing facilities while maintaining key performance indicators (KPIs) within acceptable ranges, risking unintended excessive lowering of manufacturing quality or productivity.
Innovation Solution
A facility diagnosis device that includes a deterioration prevention mode definition storage unit, a KPI calculation unit, a deterioration prevention determination unit, and a control information output unit, which together predict deterioration degrees, calculate KPIs, determine appropriate deterioration prevention modes, and output control information to maintain KPIs within acceptable ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control method is changed to prevent deterioration of the facility, then the deterioration progress is slowed, but the manufacturing quality or productivity may be excessively lowered
Solution Approach 1:
The system changes operational parameters dynamically based on the facility's deterioration state. When deterioration is detected, the control method adjusts parameters such as load distribution, operation frequency, or maintenance timing to slow deterioration while monitoring KPIs to ensure productivity remains within acceptable ranges. This resolves the contradiction by finding an optimal parameter set that balances deterioration prevention with productivity maintenance.
Solution Approach 2:
The control method transitions from static to dynamic adjustment based on real-time facility status. The system continuously monitors deterioration indicators and adapts control parameters accordingly, allowing the facility to operate in different modes (normal operation, degraded operation, maintenance mode) to balance deterioration prevention with productivity requirements.
2Reliability
If a control method is changed to prevent deterioration of the facility, then the deterioration progress is slowed, but the manufacturing quality may be excessively lowered
Solution Approach 1:
The system adjusts operational parameters to prevent deterioration while maintaining quality thresholds. When deterioration is detected, the control method modifies parameters such as processing speed, load intensity, or operation patterns in a way that slows deterioration without compromising manufacturing quality below acceptable levels.
Solution Approach 2:
The system implements feedback loops that continuously monitor both facility deterioration indicators and manufacturing quality metrics. The control method uses this feedback to adjust operational parameters in real-time, ensuring that deterioration prevention actions do not cause quality degradation beyond acceptable thresholds.
Data Source
AI summary
The progress of deterioration of a manufacturing facility is prevented while keeping KPI within an allowable range. A facility diagnosis device includes a deterioration prevention mode definition storage unit that stores information including an operation control method for preventing deterioration of a manufacturing facility or a portion thereof for each of predetermined deterioration prevention modes; a KPI calculation unit that calculates a predetermined KPI by using a deterioration degree predicted for each of the deterioration prevention modes for the manufacturing facility or the portion of the manufacturing facility, and determines whether the KPI satisfies a predetermined condition; a deterioration prevention determination unit that determines a deterioration prevention mode that should be executed from a satisfaction determination result; and a control information output unit that outputs control information on the manufacturing facility or the portion of the manufacturing facility according to the deterioration prevention mode that should be executed.